PADICON - Dr. Tanneberger GmbH

P in kW
P in kW
The optimisation system for energy costs …
The problem: energy and energy costs
Energy costs are rocketing, affecting an increasing number of manufacturing companies. Because of
their high energy requirements, foundries, especially, are often under cost pressure. The price for electrical
power in large companies is made up of two components: firstly, the price of the electrical energy
used, which makes up around 55 per cent, and secondly the demand charge, which weighs in at
around 45 per cent. The amount of electrical energy used cannot easily be changed in the short term,
but the time it is required can. Energy-based production planning can avoid cost-intensive consumption
peaks.
The solution: PADICON® –
the Parallel Difference Power Control
PADICON® can be integrated into your energy management system and is suitable for medium- and
mains-frequency furnaces. The process records the demand and power consumption and saves the data.
As the work processes are repeated, a characteristic curve is built up. Based on this curve, the process
controller synchronises all the furnaces’ separate cycle times to create a balanced load profile with no
peaks in consumption. Thus, work processes with high power consumption no longer take place independently,
but are harmonised. Peaks and troughs in demand are balanced out against one another. Until
now, production planning and control systems have not displayed the power consumption. However,
power consumption is a consistent figure which can be used to make processes transparent.
Harmonising amplitude, taking four medium-frequency furnaces as an example
Synchronisation 0% Synchronisation 50%
Furnace 1
1 minute
Furnaces 1–2
Synchronisation 75%
Furnaces 1–3
PADICON® always optimises the maximum possible spread of the parallel technological process.
Before
1 minute
AFTER!
Synchronisation 100%
When all four furnaces are operated in
parallel, peaks in demand are avoided
thanks to harmonisation.
Furnaces 1–4